WO2011160786A2 - Procédé de fabrication d'un module solaire en couches minces et module solaire en couches minces - Google Patents

Procédé de fabrication d'un module solaire en couches minces et module solaire en couches minces Download PDF

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Publication number
WO2011160786A2
WO2011160786A2 PCT/EP2011/002918 EP2011002918W WO2011160786A2 WO 2011160786 A2 WO2011160786 A2 WO 2011160786A2 EP 2011002918 W EP2011002918 W EP 2011002918W WO 2011160786 A2 WO2011160786 A2 WO 2011160786A2
Authority
WO
WIPO (PCT)
Prior art keywords
substrate
solar module
active region
liquid material
thin
Prior art date
Application number
PCT/EP2011/002918
Other languages
German (de)
English (en)
Other versions
WO2011160786A3 (fr
Inventor
Christine Cramer
Holger Brandt
Dirk Berning
Axel Nowak
Thomas Lindert
Original Assignee
Inventux Technologies Ag
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Inventux Technologies Ag filed Critical Inventux Technologies Ag
Publication of WO2011160786A2 publication Critical patent/WO2011160786A2/fr
Publication of WO2011160786A3 publication Critical patent/WO2011160786A3/fr

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/02—Details
    • H01L31/02002—Arrangements for conducting electric current to or from the device in operations
    • H01L31/02005—Arrangements for conducting electric current to or from the device in operations for device characterised by at least one potential jump barrier or surface barrier
    • H01L31/02008—Arrangements for conducting electric current to or from the device in operations for device characterised by at least one potential jump barrier or surface barrier for solar cells or solar cell modules
    • H01L31/02013—Arrangements for conducting electric current to or from the device in operations for device characterised by at least one potential jump barrier or surface barrier for solar cells or solar cell modules comprising output lead wires elements
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
    • H01L31/042—PV modules or arrays of single PV cells
    • H01L31/048—Encapsulation of modules
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
    • H02S20/00—Supporting structures for PV modules
    • H02S20/20—Supporting structures directly fixed to an immovable object
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
    • H02S40/00—Components or accessories in combination with PV modules, not provided for in groups H02S10/00 - H02S30/00
    • H02S40/30—Electrical components
    • H02S40/34—Electrical components comprising specially adapted electrical connection means to be structurally associated with the PV module, e.g. junction boxes
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/50—Photovoltaic [PV] energy

Definitions

  • the invention relates to a method for producing a thin-film solar module and to thin-film solar modules produced in this way.
  • a thin film solar module comprises a first translucent substrate, typically of glass. This element is also referred to as a front glass, as it faces the sun and light is incident on this element in the photovoltaic module.
  • a transparent conductive layer On the translucent substrate is a transparent conductive layer. This is followed by at least one photovoltaically active layer. In this layer, the incident light is converted into electricity.
  • a second conductive layer On the other side of the active layer is a second conductive layer, in particular a second transparent layer, which is for example made of the same material as the first transparent conductive layer.
  • These layers form the so-called active area.
  • Via a plastic film for example of PVB or EVA, the structure with a second substrate, preferably made of glass (also called back glass) or TEDLA film, whereby the active area is encapsulated to protect it from negative environmental influences.
  • modules are produced in a lamination process using a vacuum laminator or autoclave. This is time consuming and can only be done in batch mode.
  • the method comprises the steps of: a) providing a first translucent substrate having an active region for converting solar energy, b) providing a second substrate, c) holding the first and second substrates parallel to each other with a predetermined spacing to each other with the active region disposed between the first and second substrates, d) filling the gap with a liquid material, and e) curing the liquid material thereby encapsulating the active region.
  • the object is further achieved with the method for producing a thin-film solar module according to claim 2.
  • This comprises the steps of: f) providing a first translucent substrate having an active region for converting solar energy, g) applying a liquid material to the side of the translucent substrate with the active region, and h) curing the liquid material thereby encapsulating the active region becomes.
  • this method one can dispense with the use of an autoclave and perform the process in a continuous process.
  • the second substrate which is usually made of glass and therefore quite heavy in this process.
  • the modules become lighter and the construction easier.
  • one or more fasteners may be provided for attaching the thin film solar module to a substructure and / or one or more electrical connection devices and / or one or more reinforcing elements over the side of the translucent substrate having the active region and after step h) the hardened material integrated, in particular positively connected, be.
  • the further elements required for the use of a module can be integrated. Additional glue steps are therefore no longer necessary.
  • the connection devices can be designed so that means for strain relief of the connection cable of the active area can be poured simultaneously with the encapsulation.
  • a mold can be provided in which the liquid material is filled.
  • the mold thus any geometric structures for the encapsulation can be achieved.
  • the steps g) and h) are performed several times to form a plurality of layers. Preferred may for the several layers different shapes are used. So you can selectively arrange more material at predetermined locations.
  • the hardened material may have different thicknesses, in particular in the form of reinforcing ribs.
  • the necessary stability can be ensured by the encapsulation material and thus the use of steel, aluminum or stainless steel elements, as is still common in the known modules, can be considerably reduced. Thanks to the areas with different thicknesses, the module can be load-optimized, voltages can be compensated and / or voltage peaks can be recorded.
  • the one or more fasteners and / or the one or more attachment devices and / or the one or more reinforcement elements may be arranged to be in thicker regions of the cured material after step h).
  • the use of materials is further improved.
  • the reinforcing ribs may be at least partially arcuate.
  • the reinforcing ribs can be made possible with optimization of the material use nevertheless a uniform load on the module, since the thicker areas can extend along areas of higher voltages.
  • the liquid material can be provided so that after step h) the cured material protrudes laterally at least in sections over the edge of the substrate and / or surrounds the edge of the substrate. This also provides a protection area in a process step in order to prevent damage to the light-transmitting substrate.
  • the cured material may have reflective properties, in particular a white color, and / or protective or stabilizing properties. This eliminates the need for additional reflective layers and the structure of the module can be further simplified. With protective or stabilizing properties, the service life can be extended
  • the liquid material may be a polymer material, in particular a polyurethane plastic.
  • Polymer materials are lightweight and can be used in any Molds are poured. Thus, lighter modules can be provided, which nevertheless ensure the requirements for a long-lasting encapsulation.
  • fillers in particular fiber reinforcements and / or fillers for influencing thermal and / or electrical properties, may be added in step d) or g).
  • the structure of the module can be further optimized and optionally adapted to different purposes.
  • the additions can be designed so that inhomogeneous distributions result in the cured material.
  • the inhomogeneous distributions can be formed laterally as well as in the direction of the layer thickness.
  • the layers provided by repeating steps g) and h) may have different properties from each other to achieve such inhomogeneous distributions.
  • one layer can be made electrically conductive, while another layer is particularly reinforced.
  • the properties of the module can be further improved by the inhomogeneous addition.
  • This module may in particular be a thin-film solar module and comprises a first transparent substrate having an active region for converting solar energy, a second substrate and a layer connecting the transparent substrate and the second substrate, wherein the active region is arranged between the first and second substrates characterized in that the connecting layer is made of a cured polymer material.
  • This provides a solar module that is easier to manufacture than conventional plastic-film modules.
  • the object of the invention is likewise achieved with a solar module according to claim 15.
  • This may in particular relate to a thin-film solar module and comprises a first transparent substrate having an active region for converting solar energy, characterized in that the active region is covered by an encapsulation unit made of a cured polymer material, which also forms the back construction of the solar module.
  • a lighter module can be provided compared to the known glass-glass thin-film solar modules.
  • the polymer material may preferably have filling materials for influencing thermal and / or electrical properties.
  • the structure of the module can be further optimized and optionally adapted to different purposes.
  • the encapsulation unit can have a plurality of layers, in particular with different thermal and / or electrical properties.
  • the encapsulation unit can thus fulfill a number of tasks in addition to the encapsulation: provision of electrically conductive regions, for example to simplify the arrangement of the interfaces, rigidity of the module, etc.
  • the encapsulation unit projects laterally beyond the edge of the substrate at least in sections and / or surrounds the edge of the substrate. This allows the substrate to be protected against breakage. In particular, the assembly is facilitated.
  • the encapsulation unit can have different thicknesses.
  • the encapsulation unit can have different thicknesses.
  • further elements of a module can be inserted, or else the structure of the module can be stiffened.
  • one or more fastening elements for attaching the thin-film solar module to a substructure and / or one or more electrical connection devices and / or one or more reinforcement elements can be integrated into the encapsulation unit over the side of the light-transmissive substrate with the active region.
  • Particularly advantageous is a positive connection. This eliminates the need for expensive attachment steps such as gluing or screwing.
  • FIGS. 1a-1c show a first embodiment of the invention
  • FIGS. 2a-2d show a second embodiment of the invention
  • FIG. 3 shows a variant of the solar module which results from the method according to the second embodiment
  • FIG. 4 shows a second variant of a solar module which results from the method according to the second embodiment
  • Figure 5 is a schematic cross-sectional view taken along section line A-A of
  • FIG. 6 shows a third variant of a solar module which results from the method according to the second embodiment
  • Figure 7 schematically shows a cross-sectional view according to a fourth variant
  • FIG. 8 schematically shows a cross-sectional view according to a fifth variant.
  • FIGS. 1a to 1c schematically show a first embodiment of the invention.
  • the solar modules are shown in cross section.
  • a first transparent substrate 1 with an active region 3 for converting solar energy into electrical energy and a second substrate 5 are provided in FIG.
  • the second substrate 5 is spaced from the active region 3 but arranged substantially parallel.
  • the distance can be ensured for example via spacers, not shown here, which are arranged in the intermediate space.
  • the two structures can also be arranged in each case on a holding device, which ensure the distance.
  • the first transmissive substrate 1 and the second substrate are made of glass.
  • This element is also referred to as a front glass, as it faces the sun and light is incident on this element in the photovoltaic module.
  • the active region 3 is formed by a sequence of different layers.
  • a transparent conductive layer On the translucent substrate 1 is usually a transparent conductive layer.
  • an active layer for example a Si layer or a CdTe layer or a CiGSSe layer or else a tandem cell comprising a microcrystalline and an amorphous Si layer. In this layer, the incident light is converted into electricity.
  • a second conductive layer On the other side of the active layer becomes a second conductive layer, in particular a second transparent layer, but usually not necessarily of the same material as the first transparent conductive layer is provided.
  • SnO 2, ZnO or a metallic back contact can also be used here.
  • a reflector layer may be provided on the free surface 7 of the active layer and / or the surface 9 of the second substrate.
  • This may be a metal layer, a white film or a white-colored layer, in order to re-supply light not yet absorbed in the active layer.
  • step d) is then, as schematically indicated in Figure 1 b, the gap filled with a liquid material 1 1.
  • a frame can be placed around the assembly 13 to prevent leakage of the material.
  • the liquid material is a polymer material, in particular a polyurethane plastic.
  • step e) of claim 1 the liquid material is then cured whereby the active region 3 is encapsulated, that is isolated from the environment.
  • the hardened layer bearing the reference numeral 15.
  • an oven preferably a continuous furnace, is used.
  • the liquid material is chosen so that it has reflective properties, whereby an additional reflector layer is avoidable. This is achieved for example by a suitable color choice.
  • fillers may also be added to the liquid material to provide protective or stabilizing properties. This can for example affect the strength, the thermal expansion or the electrical properties.
  • FIGS. 2a to 2d schematically show a second method according to the invention.
  • a first translucent substrate 1 having an active region 3 for converting solar energy into electrical energy provided. This is illustrated in FIG. 2a.
  • the substrate 1 and the active region 3 are constructed in the same way as already described in connection with FIG. 1a. This description is hereby incorporated by reference.
  • FIG. 2b shows a mold 21, which is slipped over the free surface 7 of the active region 3.
  • the mold 21 comprises one or more inlet nozzles 23 via which a liquid material can be filled into the free space 25 formed between the mold 21 and the surface in accordance with feature g) of claim 2.
  • the material is again cured in an oven by thermal treatment whereby the active region 3 encapsulated becomes. Thereafter, the mold 21 can be removed, as shown in FIG. 2d, and a thin-film solar module 27, which is composed of the first substrate 1, the active region 3 and an encapsulation unit 29, is obtained.
  • the second embodiment it is possible to manufacture a solar module that is lighter in weight than the conventional glass glass products by using a plastic encapsulation unit 29.
  • the use of the mold 21 also gives the possibility of the encapsulation unit 29 to give any desired shapes.
  • the thickness of the layer 29 need not be constant over the module surface. As a result, it is possible, for example, to achieve reinforcing elements, such as ribbed structures, in one process step.
  • a multi-layer encapsulation unit 29 wherein the individual layers may have different properties with regard to strength, electrical conductivity, coefficient of expansion, etc. This can be achieved, for example, by adding filler materials, such as electrically conductive particles or reinforcing fibers, into the liquid material 11.
  • different forms 21 are used.
  • the cured material can also be partially present beyond the edge 33 on an edge region 34 on the surface of the substrate 1 in order to further optimize the edge protection.
  • FIG. 4 illustrates a second variant of a solar module which results from the method according to the second embodiment. Shown is a solar module 41 with substrate 1 and active area 3, these will not be described in detail. It is merely referred to the description above.
  • the encapsulation unit 29 "in this embodiment comprises arcuate reinforcing ribs 43 and 45, which serve to optimize the load on the module 41, to compensate for stresses and / or to absorb voltage peaks, in order to be able to produce these, it is sufficient to use a mold 21 with a corresponding structure.
  • the structure can be produced in one or more steps by using a single mold or several molds 29. For example, if the ribs 43 and 45 have different material properties compared to the base 47, two molds 21 will be used.
  • ribs can also be used according to the invention. These can also be straight.
  • connection regions 51 and 53 of the module are integrated with the reinforcing ribs 43 and 45.
  • the connection regions 51 and 53 can represent their own components, which were inserted into the still liquid material 11 and then connected to the encapsulation unit during curing of the material, or be produced directly by appropriate shaping of the encapsulation unit. In this case, for example, even a strain relief for the coming out of the active area 3 connecting strips are provided.
  • the arrangement of the connection areas in the ribs is to be seen here only as a variant. Of course, the connection areas could also be arranged outside the ribs 43 and 45.
  • Figure 4 also shows four fasteners 55, 57, 59, 61 with which the module 41 can be attached to a substructure.
  • these can be integrally formed with the encapsulation unit 29 "or represent their own elements, for example made of steel or stainless steel, which are held in the preparation in the liquid material 1 1 and after curing then integrated into the encapsulation unit 29", for example via a positive connection, are.
  • FIG. 5 shows this in a cross-sectional view along section line A-A.
  • the substrate 1 and the active region 3 can be seen there, and the encapsulation unit 29 "with the two ribs 43 and 45.
  • Profiles 63 and 65 are embedded in the encapsulation unit at the level of the fastening elements 55 and 59. These are part of the fastening elements 55 and 59. Due to the open structure, the liquid material 11 has entered the open profile and, after curing, the fastener 55 and 59 is thus retained in the encapsulation unit 29 ".
  • the profiles 63 and 65 may each extend from one fastening element 55 or 59 to the opposite fastening element 57 or 61.
  • FIG. 6 shows a third variant of a solar module 71 resulting from the method according to the second embodiment. Shown is a solar module 71 with substrate 1 and active area 3, these will not be described in detail. It is merely referred to the description above.
  • the material properties of the individual layers, in particular the thermal and / or electrical properties, can be determined by a For example, it is possible to optimize the mechanical, electrical and / or optical properties of the encapsulation unit 29 "'by means of the addition of filling materials.
  • the illustrated geometries are shown here by way of example only. Other geometries are also conceivable and according to the invention.
  • the embodiment illustrated in FIG. 6 may also be provided by integrated electrical connection devices and / or fasteners are completed according to the manner shown in Figure 4.
  • FIG. 7 shows a fourth variant with substrate 1 and active region 3.
  • the encapsulation unit 29 IV In this encapsulation unit reinforcing struts 81, 83, 85, 87 are embedded, which may preferably extend over the entire width of the module 89.
  • the reinforcing struts 81 and 87 are simultaneously provided as fastening elements and formed correspondingly thicker.
  • these struts are made of steel, aluminum or stainless steel.
  • the thickness of the cured material is adapted to the different heights of the reinforcing struts, so that forms a wavy, smooth surface.
  • FIG. 8 shows a fifth variant.
  • the areas between the reinforcing braces 91, 93, 95 of the capping unit are formed thicker v 29 in order to ensure the desired bending rigidity of the module 97 here.
  • the invention is not limited only to thin-film solar modules. Rather, it is also applicable to crystalline modules.
  • the production process is simplified and, on the other hand, a weight reduction can be achieved when using the encapsulation unit. Thanks to the integrated reinforcement elements as well as the integrable fastening elements and connecting devices, the structure of the modules and their manufacture can be further simplified

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Condensed Matter Physics & Semiconductors (AREA)
  • Electromagnetism (AREA)
  • General Physics & Mathematics (AREA)
  • Computer Hardware Design (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Power Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Sustainable Development (AREA)
  • Sustainable Energy (AREA)
  • Photovoltaic Devices (AREA)

Abstract

L'invention concerne un procédé de fabrication d'un module solaire en couches minces comportant les étapes: fourniture d'un premier substrat transparent à la lumière présentant une zone active pour convertir de l'énergie solaire; fourniture d'un deuxième substrat; maintien du premier et du deuxième substrat parallèles l'un à l'autre tout en respectant un espace prédéfini entre eux, la zone active étant disposée entre le premier et le deuxième substrat; remplissage de l'interstice avec une matière liquide; et durcissage de la matière liquide de manière à encapsuler la zone active. L'invention concerne également un procédé de fabrication d'un module solaire en couches minces comportant les étapes: fourniture d'un premier substrat transparent à la lumière présentant une zone active pour convertir de l'énergie solaire; application d'une matière liquide sur le côté du substrat transparent à la lumière comportant la zone active; et durcissage de la matière liquide de manière à encapsuler la zone active. L'invention concerne également des modules solaires ainsi fabriqués.
PCT/EP2011/002918 2010-06-25 2011-06-14 Procédé de fabrication d'un module solaire en couches minces et module solaire en couches minces WO2011160786A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102010030559.6 2010-06-25
DE102010030559A DE102010030559A1 (de) 2010-06-25 2010-06-25 Verfahren zur Herstellung eines Dünnschichtsolarmoduls und Dünnschichtsolarmodul

Publications (2)

Publication Number Publication Date
WO2011160786A2 true WO2011160786A2 (fr) 2011-12-29
WO2011160786A3 WO2011160786A3 (fr) 2012-09-07

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DE (1) DE102010030559A1 (fr)
WO (1) WO2011160786A2 (fr)

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Publication number Priority date Publication date Assignee Title
WO2014075919A1 (fr) * 2012-11-15 2014-05-22 Saint-Gobain Glass France Module photovoltaïque pourvu d'une tôle de renfort arrière
EP3597389A1 (fr) * 2018-07-18 2020-01-22 PARAT Beteiligungs GmbH Procédé de fabrication d'un composant de surface et composant avec un ensemble de cellules solaires

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GB1592581A (en) * 1977-06-16 1981-07-08 Bfg Glassgroup Solar panel
JPS60170270A (ja) * 1984-02-15 1985-09-03 Matsushita Electric Ind Co Ltd 太陽電池素子のパツケ−ジ構成法
FR2583923B3 (fr) * 1985-06-19 1987-10-23 Gravisse Philippe Procede de fabrication d'un panneau photovoltaique et panneau ainsi realise
US5008062A (en) * 1988-01-20 1991-04-16 Siemens Solar Industries, L.P. Method of fabricating photovoltaic module
DE19514908C1 (de) * 1995-04-22 1996-04-18 Ver Glaswerke Gmbh Verfahren zur Herstellung eines Solarmoduls
DE10101770A1 (de) * 2001-01-17 2002-07-18 Bayer Ag Solarmodule mit Polyurethaneinbettung und ein Verfahren zu deren Herstellung
AU2002308468A1 (en) * 2001-04-23 2002-11-05 Carmanah Technologies Inc. Potted domed solar panel capsule and traffic warning lamps incorporating same

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Publication number Publication date
DE102010030559A1 (de) 2011-12-29
WO2011160786A3 (fr) 2012-09-07

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